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Chasing BTUs

Getting The Most Out Of Your Boiler System Understanding your boiler system shouldn’t be difficult. Despite this, there’s an unfortunate trend in the industry toward over complication, cluttered with confusing terminology and explanations. Finding good information can be especially frustrating, as educational sources can quickly turn into a disguised sales pitch—written with a heavy bias toward the author’s company or product line. Whether you’re a first-time buyer, considering a replacement, or just looking for ways to improve your existing steam system, this article is for you. In it, we’ll share practical advise to help you get the most out of your steam system, regardless of your supplier or situation. Efficiency Saves You Money Efficiency has the greatest impact on your annual costs. In any boiler application, you want your steam

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Finding Hot Savings Through A Steam Generator

Interest in energy savings goes beyond furnaces, as steam generation is another area where some cable makers may be able to find savings. At American Insulated Wire’s plant in Coffeyville, Kansas, the company has realized six-digit fuel savings by changing its production line from steam boilers to steam generators from Clayton Industries. AIW, a major producer of copper building wire, manufactures single conductors encased in either a rubber or plastic insulating sheath that is extruded through a tube. The conductors are subjected to steam pressure of 250 psi to cure the rubber, converting it from “black chewing gum” to a hardened, durable and pliable sheath that maintains its shape. Until 2002, the processing steam source was two 350 BHP conventional boilers, deemed oversized, inefficient and expensive to operate. Particular problems

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Running On Steam

Cambridge, Ont.-based MW Canada is a leader in creating quality textiles for the window covering, home decorative and technical materials industries. They work with top brand names to develop exclusive designs, colors and materials to meet ever-changing consumer demands. Their products can be found at retailers such as Sears, Costco, Lowe’s, Home Depot, JC Penny’s and Blinds to Go. The company meets the specialized needs of customers by maximizing its in-house warping, weaving, knitting, dyeing and finishing, pleating, printing and laminating capabilities. Robert Berger took over as MW Canada president and CEO, the latest in the family line since his father and grandfather founded the company under the name Montreal Woollens in 1963. MW Canada relocated from its original home in Montreal to Cambridge in 1976. With 66 employees, the

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Mittal Steel’s Warren, Ohio Plant

Mittal Steel’s Warren, OH plant produces Metallurgical Coke which is used in blast furnaces for the smelting of iron. Coke is obtained by the destructive distillation of coking coals which is basically, heating the coal between 1650° F and 2000° F in a controlled atmosphere. A by-product of this process is Coke Oven Gas. COG is a low BTU (500 – 600 BTU’s/cu. Ft.) gas with considerable impurities, including sulphur and tar. This coke oven gas is typically “flared” off as a waste product. Since any boiler large enough to burn this by-product gas as a fuel to provide the amount steam used by the plant would require full time licensed opera-tors in Ohio, the Warren, OH plant does not have steam boilers. They purchase their steam from a steel

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A Case Study: Delta Trading

New Steam System Captures High Pressure Condensate Return Delta Trading needed to replace their existing boilers to comply with changing rules in the San Joaquin Air Quality District. This led them to start a search for a new boiler. Clayton Industries was contacted to inquire on how we might help them with their application of heating railcars. They were currently off-loading 5 railcars per day and wanted to increase their ability to off-load more railcars to meet increased demand in the market. Delta Trading is a 24/7 operation; consequently, they emphasized reliability and rapid response to service calls. Delta also required a boiler that was able to follow the large steam load swings which is typical for their business. Delta Trading’s required steam pressure was 150 psig to generate enough

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